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Welded components are often subjected to variable amplitude service loads, increasing the uncertainty of fatigue life due to material strength, notch geometries, defect content and residual stresses. In the case of friction stir welding (FSW) of aluminium alloys no data were found available concerning fatigue behaviour under variable amplitude loading. The purpose of this paper is to determine the fatigue strength of friction stir welds in AA6082‐T6 under constant and variable amplitude loading and analyse the validity of Miner's rule for these specific welding conditions.

Fatigue tests were carried out in a servo‐hydraulic testing machine using a stress ratio of R=0. Typified Gassner amplitude spectra were considered, using four shape exponent values. Microhardness tests were performed to characterize the Vickers hardness profile in the vicinity of the weld area. Relatively to the base material (BM), the FSW process leads to a decrease of the static mechanical properties.

Detailed examination revealed a hardness decrease in the thermo‐mechanically affected zone and the nugget zone average hardness was found to be lower than the base alloy hardness. The comparison with data collected from the literature shows that FSW specimens present higher fatigue resistance than specimens welded by metal inert gas and tungsten inert gas processes. However, they still have lower fatigue lives than the BM. Using the equivalent stress calculated by Miner's rule, a good agreement was observed between constant and variable fatigue loading results. The characteristic curve obtained for friction stir welds is higher than the International Institute of Welding (IIW) fatigue class for fusion welds with full‐penetration both‐sided butt joints.

No data are available concerning fatigue behaviour under variable amplitude loading for friction stir welds of aluminium alloys. Furthermore, this paper analyses the fatigue strength of friction stir welds in AA6082‐T6 under constant and variable amplitude loading in order to verify the validity of Miner's rule for this specific welding process. A comparison between characteristic fatigue curves, using IIW fatigue classes (FAT), is also performed.

The purpose of this paper is to investigate the use of nanoindentation with a Berkovich indenter as a method of extracting equivalent stress‐strain curves for the base metal and the welded zone of a friction stir welded aluminum alloy.

Friction stir welding is a solid‐state joining process, which emerged as an alternative technique to be used in high strength alloys that were difficult to join with conventional joining techniques. This technique has a significant effect on the local microstructure and residual stresses combined with deformation. Nano‐ and micro‐indentation are the most commonly used techniques to obtain local mechanical properties of engineering materials. In order to test the reliability of nanoindentation technique and to connect nanoscale with macroscale, the indentation hardness‐depth relation established by Nix and Gao was applied on the experimental values.

The predictions of this model were found to be in good agreement with classical hardness measurements on AA 6082‐T6 aluminum alloy. Also, finite element method provides a numerical tool to calculate complex nanoindentation problems and in correlation with gradients theories forms a well‐seried tool in order to take into account size effects.

By studying this alloy, the paper reviews fundamental principles such as stress‐strain distribution, size effects rise during nanoindentation and the applicability of finite element method, in order to take into account these issues.

The purpose of this scientific work is to simulate the fatigue damage under random loading, taking into account the mean stress effect on fatigue lifetime and using the Rainflow counting technique to assess the fatigue damage by the Ansys software. The used material is aluminum alloy 6082-T6. A comparison with literature results has confirmed this investigation in this paper.

The study of fatigue under random loading is based on the same concepts as constant loading with the addition of damage summation. The proportion of damage caused by a stress cycle depends not only on the alternating stress but also on the mean stress.

Analysis of the fatigue damage shows that the number of relative damage due to each cycle.

This paper aims to simulate the fatigue damage under random loading for aluminum alloys.

The modification of the tribological system is an essential aspect of the implementation of resource-saving processes in cold forming. As a result, the focus of this contribution is the influence of the tribological system on the full forward impact extrusion of aluminum alloy EN AW 6082 (T6) with regard to reduction of friction and wear.

The investigations included a variation of lubricant and die treatment. Friction, wear and the mean arithmetic height Sa were used as evaluation criteria. The aim was to find a suitable die surface treatment and a suitable lubricant on the basis of the evaluation criteria.

The experiments indicated that each of the selected tribological systems prevents physical metallic contact between tool and workpiece and thus prevents the formation of wear. Nevertheless, differences were found in the areas of smoothing of workpiece surfaces and adhesive strength of lubricants.

As general cause effect relationships between die coating and lubricant are not known in the field of bulk metal forming of aluminum, fundamental investigations are described below. The investigations focus on the influence of the material and the tribological system on friction as well as wear.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2019-0316

Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal.

In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated.

The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R²) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function.

Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

The purpose of this scientific work is to simulate the fatigue damage under random loading taking into account the mean stress effect on fatigue lifetime and using the rainflow counting technique to assess the fatigue damage.

The study of fatigue under random loading is based on same concepts which as constant loading with addition of damage summation. The damage of materials due a stress cycle depends not only on the alternating stress but also on the mean stress.

The cycles counting simulation method allows quantifying the hysteresis loops, even if for small amplitude stresses.

The cycles are low or medium; the damage occurs most often, the higher values of alternating stresses cause the most failure of materials.

Lightweight alloys are of major concern, due to their applicability, in transport and industry applications. The purpose of this paper is to perform a comprehensive analysis of time dependent properties of aluminum alloy by nanoindentation technique, through investigation of creep behavior. Additionally, possible explanations on the time dependent behavior and the influence of the hold period at maximum load and the loading rate on the elastic modulus and hardness results are also analyzed and discussed.

In this work, a comprehensive analysis of time dependent properties of aluminum alloy by nanoindentation technique was performed, by varying the loading rate, the maximum applied load and the loading time. The stress exponent values are derived from the displacement‐holding time curves. The present experimental setup includes three different approaches: variation of loading rate, maximum applied load and loading time. The creep deformation mechanisms of the alloy, which are dependent on experiment setup, are discussed and the characteristic “elbow” behavior in the unloading part of the curves is also reported.

The authors found that the stress exponent values obtained are dependent on the applied peak loads and indentation loading rates. Nanoindentation creep testing of aluminum AA6082‐T6 revealed significant creep displacements, where the strain rate reached a steady state after a certain time and the stress decreased with time as the displacement increased during the creep process. The slopes of strain rate versus stress curves (exponent of power‐law creep) for different maximum loads and various holding times, were investigated.

The stress exponent of the constant‐load indentation creep, in all three types of experiments, was found to reduce at low load region. In case of different holding load and time, the stress exponent increased almost linearly and increased very rapidly as the indent size increased, exhibiting an intense size effect.

The purpose of this paper is to join an anodized aluminium alloy AA6061 sheet with high-density polyethylene (HDPE) using friction spot process.

The surface of AA6061 sheet was anodized to increase the pores’ size. A lap joint configuration was used to join the AA6061 with HDPE sheets by the friction spot process. The joining process was carried out using a rotating tool of different diameters: 14, 16 and 18 mm. Three tool-plunging depths were used – 0.1, 0.2 and 0.3 mm – with three values of the processing time – 20, 30 and 40 s. The joining process parameters were designed according to the Taguchi approach. Two sets of samples were joined: the as-received AA6061/HDPE and the anodized AA6061/HDPE.

Frictional heat melted the HDPE layers near the lap joint line and penetrated it through the surface pores of the AA6061 sheet via the applied pressure of the tool. The tool diameter exhibited higher effect on the joint strength than processing time and the tool-plunging depth. Specimens of highest and lowest tensile force were failed by necking the polymer side and shearing the polymer layers at the lap joint, respectively. Molten HDPE was mechanically interlocked into the pores of the anodized surface of AA6061 with an interface line of 18-m width.

For the first time, HDPE was joined with the anodized AA6061 by the friction spot process. The joint strength reached an ideal efficiency of 100 per cent.

Engineering components/structures with geometric discontinuities normally bear complex and variable loads, which lead to a multiaxial and random/variable amplitude stress/strain state. Hence, this study aims how to effectively evaluate the multiaxial random/variable amplitude fatigue life.

Recent studies on critical plane method under multiaxial random/variable amplitude loading are reviewed, and the computational framework is clearly presented in this paper.

Some basic concepts and latest achievements in multiaxial random/variable amplitude fatigue analysis are introduced. This review summarizes the research status of four main aspects of multiaxial fatigue under random/variable amplitude loadings, namely multiaxial fatigue criterion, method for critical plane determination, cycle counting method and damage accumulation criterion. Particularly, the latest achievements of multiaxial random/variable amplitude fatigue using critical plane methods are classified and highlighted.

This review attempts to provide references for further research on multiaxial random/variable amplitude fatigue and to promote the development of multiaxial fatigue from experimental research to practical engineering application.

The purpose of this paper is to evaluate temperature and properties at interface of AISI 1040 steels joined by friction welding.

In this study, AISI 1040 medium carbon steel was used in the experiments. Firstly, optimum parameters of the friction welding were obtained by using a statistical analysis. Later, the microstructures of the heat‐affected zone are presented along with micro hardness profiles for the joints. Then, the temperature distributions are experimentally obtained in the interface of the joints that is formed during the friction welding of 1040 steels with the same geometry. This study was carried out by using thermocouples at different locations of the joint‐interface. The results obtained were compared with previous studies and some comments were made about them.

It was discovered that temperature had a substantial effect on the mechanical and metallurgical properties of the material.

The maximum temperature in the joint during frictional heating depends not only on the pressure, but also on the temperature gradient which depends on the rotational speed in particular. It is important to note that the measurement process was successfully accomplished in this study although it was particularly difficult to obtain temperature due to the large deformations at the interface. Future work could be concentrated on the temperature measurement of the joined materials.

Temperature is one of the most important of all physical quantities in industry. Its measurement plays a key part in industrial quality and process control, in the efficient use of energy and other resources, in condition monitoring and in health and safety. This paper contributes to the literature about temperature measurement in welded, brazed and soldered materials.

The main value of this paper is to contribute and fulfill the influence of the interface temperature on properties in welding of various materials that is being studied so far in the literature.